Conductive, Polypyrrole Coating on Mullite/Alumina Fibers for Electrophoretic Deposition of Oxide Matrices

Mullite/alumina fibers (Nextel™ 720) have been rendered conductive for electrophoretic deposition (EPD) by coating with polypyrrole (Ppy) from an aqueous solution of pyrrole (Py). The polymer coating was characterized by thermogravimetric (TG) analysis, scanning electron microscopy (SEM), and conductivity measurements. The Ppy coating thickness is ∼0.1 μm and the fiber resistance 1–2 (kΩ/cm)/fiber tow. A maximum conductivity of ∼48 S/cm was achieved from a 0.005 M pyrrole solution. A Nextel 720/Al ₂ O ₃ composite was synthesized using Ppy‐coated fibers as the cathode in an EPD cell. The green and sintered microstructures of the resultant composites are reported.